CN114133224B - Refractory material for rotary kiln and construction method thereof - Google Patents
Refractory material for rotary kiln and construction method thereof Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
- C04B35/103—Refractories from grain sized mixtures containing non-oxide refractory materials, e.g. carbon
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
- F27D1/16—Making or repairing linings increasing the durability of linings or breaking away linings
- F27D1/1626—Making linings by compacting a refractory mass in the space defined by a backing mould or pattern and the furnace wall
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3427—Silicates other than clay, e.g. water glass
- C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6567—Treatment time
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/74—Physical characteristics
- C04B2235/77—Density
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
Abstract
The invention provides a refractory material for a rotary kiln and a construction method thereof, belonging to the technical field of refractory materials, wherein the refractory material comprises the following components: aggregate, matrix material and fiber material; the matrix material comprises 5-15 parts of silicon carbide fine powder, 5-15 parts of mullite micro powder, 5-10 parts of alumina fine powder and 5-15 parts of corundum fine powder; the aggregate comprises 40-60 parts of bauxite clinker, 10-20 parts of zircon and 30-50 parts of corundum fine sand; the fiber material comprises 5-10 parts of aluminum silicate fiber, 3-5 parts of polypropylene fiber, 5-8 parts of stainless steel fiber and 3-5 parts of explosion-proof fiber. The refractory material can solve the problem of short service life of the refractory material, remarkably prolong the service life of the refractory material, further prolong the service life of equipment such as a rotary kiln and the like and reduce maintenance frequency; the refractory material has high compressive strength, is not easy to break and other damages in the using process, does not influence the operation period of equipment, and reduces the overhaul cost and the production cost.
Description
Technical Field
The invention relates to the technical field of refractory materials, in particular to a refractory material for a rotary kiln and a construction method thereof.
Background
Rotary kilns are the main equipment used in industrial processes, and are usually lined with refractory materials. The refractory material for the industrial rotary kiln is required to bear high temperature, erosion abrasion and stress of materials, so the used refractory material is required to have the characteristics of high temperature resistance, corrosion resistance, good thermal shock resistance, high refractoriness under load and the like. For example, the front kiln mouth of the rotary kiln is not only a discharge hole, but also a cooling part. On one hand, the front kiln mouth needs to bear the heat load and the scouring action of the burnt clinker with high temperature, on the other hand, the front kiln mouth needs to receive the pressure action of high air volume from a cooling machine, and the temperature of the kiln mouth can change repeatedly between high temperature and lower temperature, so that the refractory material is required to have good high-temperature wear resistance, scouring resistance and thermal shock resistance.
Under the working condition of production and operation of the industrial rotary kiln, the phenomenon of falling off of the refractory material of the rotary kiln, particularly large-area damage and falling off of the refractory material in a high-temperature area, often occurs because the industrial rotary kiln works in a high-temperature and high-impact environment for a long time. With the continuous damage and the falling of the refractory materials, the continuity of production is often affected, and the loss is caused to enterprises. In addition, the service life of the rotary kiln can be seriously influenced by the damage of the refractory material of the rotary kiln. Common causes of damage to rotary kiln refractories include: bearing the comprehensive effects of mechanical stress, material friction, thermal stress, air flow, chemical erosion and the like in a rotating state for a long time. The existing refractory material is high temperature resistant and corrosion resistant, but has low wear resistance, poor thermal shock resistance, poor thermal stability, low refractoriness under load, easy occurrence of cracks and damage, short service life and need to be frequently stopped to replace or repair the refractory material of the rotary kiln. However, even if the rotary kiln refractory is damaged or falls off, the part of the refractory is repaired, but if the repairing method is not proper, the repaired rotary kiln refractory brick and the repaired castable still fall off continuously, so that the rotary kiln refractory needs to be stopped and overhauled.
Therefore, the invention provides an improved high-performance refractory material and a construction method, which are used for prolonging the service life of the refractory material, further prolonging the service life of a rotary kiln and reducing the maintenance frequency.
Disclosure of Invention
In a first aspect, the invention provides a refractory material for a rotary kiln, which is used for solving the problem of short service life of the refractory material so as to prolong the service life of the refractory material, further prolong the service life of equipment such as a rotary kiln and reduce the maintenance frequency; the refractory material has high compressive strength, is not easy to break and other damages in the using process, does not influence the operation period of equipment, and reduces the overhaul cost and the production cost.
Specifically, the present invention provides a refractory material comprising: aggregate, matrix material and fiber material;
the matrix material comprises 5-15 parts of silicon carbide fine powder, 5-15 parts of mullite micro powder, 5-10 parts of alumina fine powder and 5-15 parts of corundum fine powder;
the aggregate comprises 40-60 parts of bauxite clinker, 10-20 parts of zircon and 30-50 parts of corundum fine sand;
the fiber material comprises 5-10 parts of aluminum silicate fiber, 3-5 parts of polypropylene fiber, 5-8 parts of stainless steel fiber and 3-5 parts of explosion-proof fiber. According to the technical scheme, the aggregate is matched with the matrix material to form the main body with high wear resistance and corrosion resistance, the fiber material is added into the main body, a net-shaped attachment frame can be formed for the main body, the overall performance of the refractory material is maintained, and the fracture resistance and the scouring resistance of the refractory material are enhanced.
In a specific embodiment, the particle size of each raw material in the matrix material is 0.1-1mm; the particle size of each raw material in the aggregate is 1-10mm; the particle size of each raw material in the fiber additive is 5-10mm. The aggregate has the function of a framework, has good erosion resistance, high refractoriness, good wear resistance and thermal shock stability, is convenient for construction, and increases the mechanical strength of the material. The matrix material can fill the gaps of the aggregate to form compact accumulation, so that the internal density of the material is improved, and cementation or sintering can be promoted, so that the material has better construction performance. The fiber material can effectively absorb microcracks in the refractory material, improve the heat insulation and wear resistance, toughness, thermal shock stability and spalling resistance of the refractory material, reduce the change rate of a high-temperature cold state line and reduce the damage to the refractory material caused by frequent starting and stopping.
In a specific embodiment, the refractory material further comprises 5 to 10 parts by weight of a binder; the bonding agent is a mixture of sulfite pulp waste liquid and aluminum sol. The bonding agent can effectively join raw materials with various particle sizes, reduce the internal friction force among the raw materials, greatly improve the sintering and mechanical properties of the material, solve the problems of loose internal tissues, low strength and easy abrasion of the material, and ensure that the hardened material formed by construction is stable and reliable and has longer service life.
Further, the weight ratio of the sulfite pulp waste liquor to the aluminum sol is 1.5-3.5.
In a second aspect, the present invention provides a method for preparing a refractory material for a rotary kiln, comprising:
mixing the components of the aggregate and the matrix material to form a solid mixture;
mixing the components of the binding agent, adding water, stirring and dispersing to form binding agent slurry;
mixing the components of the fiber material, then adding the fiber material into the bonding agent slurry, and stirring to form a slurry mixture; and the number of the first and second groups,
and adding the solid mixture into the slurry mixture, and uniformly stirring to obtain the refractory material for construction. The refractory material can be used for lining and sealing of industrial kiln thermal equipment, and is also suitable for various thermal melting tanks, flues and the like.
In a specific embodiment, in the step of forming the binder slurry, water is added in an amount of 5 to 15wt% based on the total weight of the components of the raw refractory material.
In a specific embodiment, in each step of the preparation method, mechanical stirring is adopted, and the stirring time is not less than 30min.
Further, the stirring time is 30-60min.
According to the invention, the prepared refractory material can also be directly used for repairing the linings of equipment such as kilns and the like, the service life of the refractory material is prolonged, the refractory material is convenient to construct, can be molded at will, and is suitable for repairing parts such as blast furnaces, electric furnace melting tanks, rotary kilns, various flues, tanks and the like in cement kilns.
In a third aspect, the present invention provides a method for constructing a refractory material for a rotary kiln, comprising:
cleaning construction parts: cleaning sundries and polishing the part to be constructed, and cleaning an oxide layer and the like on the surface of the part;
pouring: mounting a fixed structure at a part to be constructed, dividing the fixed structure into a plurality of pouring units, pouring prepared refractory materials which can be used for construction into the fixed structure in sequence, vibrating and forming, then arranging exhaust holes, filling ceramic fiber blankets in gaps after the fixed structure is removed, and then carrying out hardening maintenance;
baking: and after the material is hardened, baking the material according to a temperature rise curve to further promote the curing and shaping of the refractory material, thus finishing the construction.
In specific embodiments, the spacing of the vents is 200mm by 200mm or 400mm by 400mm. The full vibration after the refractory material is poured can ensure that the integral structure of the refractory material is more compact, the mechanical strength of the refractory material is favorably enhanced, the phenomena of collapse and the like in the step of baking the furnace can be avoided, the construction quality of equipment is ensured, and the construction efficiency is improved.
In a specific embodiment, the temperature rise profile is as follows: heating from room temperature to 100 ℃ for 12h, keeping the temperature constant for 10h, heating to 200 ℃ for 10h, keeping the temperature constant for 72h, heating to 350 ℃ for 10h, keeping the temperature constant for 48h, heating to 650 ℃ for 16h, keeping the temperature constant for 24h, heating to 850 ℃ for 10h, keeping the temperature constant for 16h, heating to 1050 ℃ for 10h, keeping the temperature constant for 8h, and naturally cooling. The baking furnace is used for evaporating water in the formed refractory material, promoting sintering at high temperature and improving the mechanical property of the refractory material.
According to the invention, the refractory material has a room-temperature compressive strength (110 ℃ x 24 h) of not less than 65MPa, a room-temperature flexural strength (110 ℃ x 24 h) of not less than 8MPa, a refractoriness under load (0.2 MPa x 4%) of more than 1500 ℃, and a bulk density of not less than 2.7g/cm 3 The change of the heating permanent line (1100 ℃ C.. Times.3 h) was. + -. 0.4%.
The refractory material provided by the invention can realize the following beneficial effects by reasonably proportioning and modulating the raw materials and assisting with an effective construction means:
1) The refractory material has the advantages of high compressive strength, good wear resistance, good thermal shock performance and strong corrosion resistance to alkali, sulfur, chlorine and other media, and simultaneously has higher refractoriness under load, is not easy to break and other damages in the use process, and effectively prolongs the service life.
2) The preparation method of the refractory material can enhance the wear resistance, improve the strength, the refractoriness and the corrosion resistance of the product, reasonably arrange the steps according to the functions of all the components, exert the functions of all the components to the maximum, improve the integrity of the refractory material and effectively gain all the performances of the refractory material.
3) After the refractory material is prepared, the construction is convenient, the construction quality is convenient to ensure, the construction period is shortened, the consumption of the castable is reduced, the service life of the rotary kiln is prolonged, the times of parking, maintenance and replacement can be reduced to the maximum extent, the continuous production can be ensured, the operation period is not influenced, and the overhaul cost and the production cost are reduced.
4) The material proportion of the refractory material, the preparation method thereof and the construction method are combined with each other, so that the integrity of the refractory material can be improved, the refractory material has high wear resistance, high corrosion resistance and high thermal shock resistance, the fracture resistance and wear and scouring resistance of the refractory material are enhanced, the service life is long, the replacement period is long, the production cost is obviously reduced, and the production efficiency is greatly improved.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are a part of the embodiments of the present invention, but not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art based on the embodiments of the present invention without any inventive step, also belong to the scope of protection of the present invention.
In other embodiments, al is present in the refractory 2 O 3 The weight ratio of (A) is not less than 70%.
In other embodiments, there is additionally provided a repair method using the above refractory material, specifically as follows: cleaning up sundries at the damaged part, preparing the refractory material for construction according to the preparation method, pouring the refractory material into a material spraying machine when the refractory material is fully stirred until the refractory material is moist and free of agglomeration, adjusting the pressure of a spray gun to 0.5-0.7MPa for spraying, spraying the refractory material to the thickness flush with the surface of the damaged part at one time, hardening and curing, curing in an oven, finishing the repair, and putting the equipment into use again.
By adopting the technical scheme, the repairing method can effectively prolong the service life of the plateau equipment, obtains good results in field application, has good viscosity, can be fully combined and compatible with the original structure, greatly reduces the maintenance shutdown and replacement times, enables the production to be continuously carried out, and reduces the maintenance cost and the production cost.
Example 1:
a method for preparing a refractory material for a rotary kiln comprises the following steps:
(1) Taking the components of the aggregate and the matrix material according to parts by weight respectively for later use, then mixing the raw materials, and uniformly stirring to obtain a solid mixture; the base material comprises 5 parts of silicon carbide fine powder, 5 parts of mullite micro powder, 5 parts of alumina fine powder and 5 parts of corundum fine powder, and the particle size of each raw material in the base material is 0.1-1mm; the aggregate comprises 40 parts of bauxite clinker, 10 parts of zircon and 30 parts of corundum fine sand, and the particle size of each raw material in the aggregate is 1-10mm.
(2) Uniformly mixing two components of sulfite pulp waste liquor and aluminum sol in a binding agent according to the weight ratio of 1.5, then adding water into the mixture, and fully stirring and dispersing for 30min to obtain binding agent slurry; the amount of the water added is 5wt% based on the total weight of the raw materials of the refractory.
(3) Mixing the components of the fiber material according to the weight ratio, adding the obtained mixture into the bonding agent slurry, and fully stirring for 30min to obtain a slurry mixture; the fiber material comprises 5 parts of aluminum silicate fiber, 3 parts of polypropylene fiber, 5 parts of stainless steel fiber and 3 parts of explosion-proof fiber; the particle size of each raw material in the fiber additive is 5-10mm.
(4) And adding the solid mixture into the slurry mixture, and uniformly stirring and mixing for 30min to obtain the refractory material for construction.
Example 2:
a construction method of a refractory material for a rotary kiln comprises the following steps:
1) Cleaning construction parts: cleaning and polishing sundries on the part to be constructed, and cleaning an oxide layer and the like on the surface of the part.
2) Pouring: installing a fixed structure at a part to be constructed, dividing the fixed structure into a plurality of pouring units, pouring the refractory material which is prepared in the embodiment 1 and can be used for construction into the fixed structure in sequence, vibrating the refractory material for forming, arranging vent holes with the spacing of 200mm multiplied by 200mm, filling a ceramic fiber blanket in a gap after the fixed structure is removed, and then performing hardening maintenance;
3) Baking: after the material is hardened, baking the furnace according to a temperature rise curve to further promote the curing and shaping of the refractory material, thereby completing construction; the temperature rise curve is as follows: heating from room temperature to 100 ℃ for 12h, keeping the temperature for 10h, heating to 200 ℃ for 10h, keeping the temperature for 72h, heating to 350 ℃ for 10h, keeping the temperature for 48h, heating to 650 ℃ for 16h, keeping the temperature for 24h, heating to 850 ℃ for 10h, keeping the temperature for 16h, heating to 1050 ℃ for 10h, keeping the temperature for 8h, and naturally cooling.
Example 3:
a construction method of a refractory material for a rotary kiln comprises the following steps:
(1) Taking the components of the aggregate and the matrix material according to parts by weight respectively for later use, then mixing the raw materials, and uniformly stirring to obtain a solid mixture; the matrix material comprises 10 parts of silicon carbide fine powder, 10.5 parts of mullite micro powder, 8 parts of alumina fine powder and 10 parts of corundum fine powder, and the particle size of each raw material in the matrix material is 0.1-1mm; the aggregate comprises 55 parts of bauxite clinker, 15 parts of zircon and 40 parts of corundum fine sand, and the particle size of each raw material in the aggregate is 1-10mm.
(2) Uniformly mixing two components of sulfite pulp waste liquor and aluminum sol in a binding agent according to a weight ratio of 1; the amount of water added was 10wt% based on the total weight of the raw materials of the refractory.
(3) Mixing the components of the fiber material according to the weight ratio, adding the obtained mixture into the bonding agent slurry, and fully stirring for 45min to obtain a slurry mixture; the fiber material comprises 7.5 parts of aluminum silicate fiber, 3.5 parts of polypropylene fiber, 7 parts of stainless steel fiber and 4 parts of explosion-proof fiber; the particle size of each raw material in the fiber additive is 5-10mm.
(4) And adding the solid mixture into the slurry mixture, and uniformly stirring for 45min to obtain the refractory material for construction.
(5) Cleaning construction parts: cleaning sundries and polishing the part to be constructed, and cleaning an oxide layer and the like on the part.
(6) Pouring: mounting a fixed structure at a part to be constructed, dividing the fixed structure into a plurality of pouring units, pouring prepared refractory materials which can be used for construction into the fixed structure in sequence, vibrating and molding, arranging vent holes with the distance of 400mm multiplied by 400mm, filling ceramic fiber blankets in gaps after the fixed structure is removed, and then hardening and maintaining;
(7) Baking: after the material is hardened, baking the material in a furnace according to a heating curve to further promote the curing and shaping of the refractory material, thus finishing the construction; the temperature rise curve is as follows: heating from room temperature to 100 ℃ for 12h, keeping the temperature for 10h, heating to 200 ℃ for 10h, keeping the temperature for 72h, heating to 350 ℃ for 10h, keeping the temperature for 48h, heating to 650 ℃ for 16h, keeping the temperature for 24h, heating to 850 ℃ for 10h, keeping the temperature for 16h, heating to 1050 ℃ for 10h, keeping the temperature for 8h, and naturally cooling.
Example 4:
in the embodiment, the refractory material and the preparation method thereof are optimized, and the measures are as follows: the components of the bonding agent adopted in the embodiment comprise: the adhesive comprises sulfite pulp waste liquor, alumina sol, sodium hexametaphosphate and zirconium sulfate, and the adhesive comprises 3wt% of sodium hexametaphosphate and 5wt% of zirconium sulfate. The components of the newly-formed binding agent are mutually matched, a net structure can be fully formed under the action of mechanical shearing to enhance the condensation performance, and the deformation stress among other raw materials can be effectively relieved by utilizing the molten state or possible lattice change during baking, so that the compactness among refractory materials is further improved, and the erosion resistance and the mechanical performance of the refractory materials are further improved.
In a specific embodiment, the construction method of the refractory for a rotary kiln is the same as that in example 3 except for the following steps: in the step (2), taking sulfite pulp waste liquor and aluminum sol, uniformly mixing according to a weight ratio of 1; the amount of water added was 10wt% based on the total weight of the raw materials of the refractory.
Example 5:
a construction method of a refractory material for a rotary kiln comprises the following steps:
(1) Taking the components of the aggregate and the matrix material according to parts by weight respectively for later use, then mixing the raw materials, and uniformly stirring to obtain a solid mixture; the base material comprises 15 parts of silicon carbide fine powder, 15 parts of mullite micro powder, 10 parts of alumina fine powder and 15 parts of corundum fine powder, and the particle size of each raw material in the base material is 0.1-1mm; the aggregate comprises 60 parts of bauxite clinker, 50 parts of zircon and 50 parts of corundum fine sand, and the particle size of each raw material in the aggregate is 1-10mm.
(2) Uniformly mixing two components of sulfite pulp waste liquor and aluminum sol in the binding agent according to the weight ratio of 1:3.5, then adding water into the mixture, and fully stirring and dispersing for 60min to obtain binding agent slurry; the amount of water added was 15wt% based on the total weight of the raw materials of the refractory.
(3) Mixing the components of the fiber material according to the weight ratio, adding the obtained mixture into the bonding agent slurry, and fully stirring for 60min to obtain a slurry mixture; the fiber material comprises 10 parts of aluminum silicate fiber, 5 parts of polypropylene fiber, 8 parts of stainless steel fiber and 5 parts of explosion-proof fiber; the particle size of each raw material in the fiber additive is 5-10mm.
(4) And adding the solid mixture into the slurry mixture, and uniformly stirring and mixing for 60min to obtain the refractory material for construction.
(5) Cleaning construction parts: cleaning sundries and polishing the part to be constructed, and cleaning an oxide layer and the like on the part.
(6) Pouring: mounting a fixed structure at a part to be constructed, dividing the fixed structure into a plurality of pouring units, pouring prepared refractory materials which can be used for construction into the fixed structure in sequence, vibrating and molding, arranging vent holes with the distance of 400mm multiplied by 400mm, filling ceramic fiber blankets in gaps after the fixed structure is removed, and then hardening and maintaining;
(7) Baking: after the material is hardened, baking the material in a furnace according to a heating curve to further promote the curing and shaping of the refractory material, thus finishing the construction; the temperature rise curve is as follows: heating from room temperature to 100 ℃ for 12h, keeping the temperature for 10h, heating to 200 ℃ for 10h, keeping the temperature for 72h, heating to 350 ℃ for 10h, keeping the temperature for 48h, heating to 650 ℃ for 16h, keeping the temperature for 24h, heating to 850 ℃ for 10h, keeping the temperature for 16h, heating to 1050 ℃ for 10h, keeping the temperature for 8h, and naturally cooling.
Example 6:
the construction method of the refractory for a rotary kiln of the present example was the same as that in example 5, except for the following steps: in the step (2), taking sulfite pulp waste liquor and aluminum sol, uniformly mixing according to a weight ratio of 1:3.5, then adding 3wt% of sodium hexametaphosphate and 5wt% of zirconium sulfate, adding water, and fully stirring and dispersing for 60min to obtain a binder slurry; the amount of water added was 15wt% based on the total weight of the raw materials of the refractory.
Comparative example 1:
the construction method of the refractory for a rotary kiln in this comparative example was the same as that in example 4, except for the following steps: in the step (2), uniformly mixing the sulfurous acid pulp waste liquid and the alumina sol according to a weight ratio of 1; the amount of water added was 10wt% based on the total weight of the raw materials of the refractory.
Comparative example 2:
the construction method of the refractory for a rotary kiln in this comparative example was the same as that in example 4, except for the following steps: in the step (2), taking sulfite pulp waste liquor and aluminum sol, uniformly mixing according to a weight ratio of 1; the amount of water added was 10wt% based on the total weight of the raw materials of the refractory.
Experimental example 1:
evaluation of the Properties of different refractory materials
The experimental method comprises the following steps: the same weight of refractory materials usable for construction was prepared according to the methods of examples 3 to 6 and comparative examples 1 to 2, respectively. Pouring the prepared refractory material into a mould with the size of 40mm multiplied by 160mm, vibrating for 2min, then maintaining the obtained test mould at room temperature for 24h, demoulding, standing at room temperature for 24h, drying the test mould at 110 ℃ for 24h, and preserving heat for 3h under the air conditions of 1000 ℃ and 1600 ℃; the test specimens are tested for volume density, normal temperature and post-firing compressive strength and flexural strength according to GB/T2997-2015, GB/T5072-2008, GB/T3001-2017 and the like. The slag corrosion resistance of the refractory material is tested by adopting a static crucible method, a sample is a cubic block of 70mm multiplied by 70mm, the size of an internal crucible is phi =40mm, h =40mm, 30g of steel slag is weighed and placed in the internal crucible of the sample, the sample is insulated for 3h under the air condition of 1600 ℃, after cooling, the section of the slag corrosion sample is observed, and the slag corrosion area rate after the steel slag corrosion is tested and calculated. Other properties were tested according to the national standard. Each set was set up with 5 replicates. The results are shown in table 1 below.
TABLE 1 results of the Performance test of different refractory materials
The results show that the refractory materials prepared by the methods of examples 3-6 and comparative examples 1-2 all show excellent mechanical properties, have higher refractoriness, excellent medium erosion resistance, higher refractoriness under load, higher high-temperature strength and better thermal stability. After construction, the service life of the equipment can be effectively prolonged, and meanwhile, the overhaul working time is reduced to the maximum extent, and the overhaul cost and the production cost are reduced.
In addition, after the samples of the example 3 and the comparative examples 1-2 are corroded by the steel slag, the edges of corroded areas are extremely irregular, while the edge areas of the samples of the example 4 are smoother, and the corroded area rate is obviously lower than that of other samples; also, a comparison of examples 5 and 6 shows that example 6 also has a significantly lower eroded area rate than example 5. The possible reasons are that the slag enters the interior of the material for erosion damage through infiltration and chemical dissolution erosion, and the materials of examples 4 and 6 have better condensation effect among the components in the preparation process, further improve the compactness among the refractory materials, improve the mechanical properties of the refractory materials, show more excellent erosion resistance and reduce partial erosion damage.
Finally, it should be noted that the above embodiments are only used for illustrating the technical solutions of the present invention, and not for limiting the same; while the invention has been described in detail and with reference to the foregoing embodiments, those skilled in the art will appreciate that; the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (8)
1. A refractory for a rotary kiln, comprising: aggregate, matrix material and fiber material;
the matrix comprises 5-15 parts of silicon carbide fine powder, 5-15 parts of mullite micro powder, 5-10 parts of alumina fine powder and 5-15 parts of corundum fine powder;
the aggregate comprises 40-60 parts of bauxite clinker, 10-20 parts of zircon and 30-50 parts of corundum fine sand;
the fiber material comprises 5-10 parts of aluminum silicate fiber, 3-5 parts of polypropylene fiber, 5-8 parts of stainless steel fiber and 3-5 parts of explosion-proof fiber;
the refractory material also comprises 5-10 parts by weight of a bonding agent; the components of the binding agent comprise sulfite pulp waste liquid, alumina sol, sodium hexametaphosphate and zirconium sulfate; the binding agent comprises 3wt% of sodium hexametaphosphate and 5wt% of zirconium sulfate; the weight ratio of the sulfurous acid pulp waste liquid to the aluminum sol is 1.5-3.5.
2. The refractory for a rotary kiln according to claim 1, characterized in that: the particle size of each raw material in the base material is 0.1-1mm; the particle size of each raw material in the aggregate is 1-10mm; the particle size of each raw material in the fiber additive is 5-10mm.
3. A method for preparing a refractory material for a rotary kiln according to claim 1 or 2, comprising:
mixing the components of the aggregate and the matrix material to form a solid mixture;
mixing the components of the binding agent, adding water, stirring and dispersing to form binding agent slurry;
mixing the components of the fiber material, then adding the fiber material into the bonding agent slurry, and stirring to form a slurry mixture; and the number of the first and second groups,
and adding the solid mixture into the slurry mixture, and uniformly stirring to obtain the refractory material for construction.
4. The method of claim 3, wherein: in the step of forming the binder slurry, the amount of water added is 5-15wt% of the total weight of the components of the raw refractory material.
5. The method of claim 3, wherein: in each step of the preparation method, mechanical stirring is adopted, and the stirring time is not less than 30min.
6. A method of constructing a refractory for a rotary kiln as defined in claim 1 or 2, comprising:
cleaning construction parts: cleaning sundries and polishing the part to be constructed, and cleaning an oxide layer on the part;
pouring: installing a fixed structure at a position to be constructed, dividing the fixed structure into a plurality of pouring units, pouring the refractory material of claim 1 or 2 into the fixed structure in sequence, vibrating and forming, then arranging exhaust holes, filling ceramic fiber blankets in gaps after the fixed structure is removed, and then performing hardening maintenance;
baking: and after the material is hardened, baking the material in a furnace according to a heating curve to further promote the curing and shaping of the refractory material, thus finishing the construction.
7. The method of claim 6, wherein: the distance between the exhaust holes is 200mm multiplied by 200mm or 400mm multiplied by 400mm.
8. The method of claim 6, wherein: the temperature rise curve is as follows: heating from room temperature to 100 ℃ for 12h, keeping the temperature for 10h, heating to 200 ℃ for 10h, keeping the temperature for 72h, heating to 350 ℃ for 10h, keeping the temperature for 48h, heating to 650 ℃ for 16h, keeping the temperature for 24h, heating to 850 ℃ for 10h, keeping the temperature for 16h, heating to 1050 ℃ for 10h, keeping the temperature for 8h, and naturally cooling.
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| CN102674859A (en) * | 2012-05-24 | 2012-09-19 | 洛阳理工学院 | Refractory castable for kilneye and kiln head cover of rotary kiln |
| CN104513041A (en) * | 2013-09-29 | 2015-04-15 | 佛山市顺德区北航先进技术产业基地有限公司 | Inorganic fiber reinforced heat insulation board |
| CN105367095A (en) * | 2015-11-19 | 2016-03-02 | 长兴兴鹰新型耐火建材有限公司 | Fireproof pouring material used for cement kiln tertiary air duct and preparation method thereof |
| CN106370010A (en) * | 2016-08-31 | 2017-02-01 | 安徽芜湖海螺建筑安装工程有限责任公司 | Novel liner structure implementation scheme for cement kiln opening |
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| JPH10101441A (en) * | 1996-09-26 | 1998-04-21 | Asahi Glass Co Ltd | Composition for castable refractory and formation of furnace wall using the same composition |
| CN104829245A (en) * | 2015-04-10 | 2015-08-12 | 浙江锦诚耐火材料有限公司 | Kilneye prefabricated component for cement kiln |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102674859A (en) * | 2012-05-24 | 2012-09-19 | 洛阳理工学院 | Refractory castable for kilneye and kiln head cover of rotary kiln |
| CN104513041A (en) * | 2013-09-29 | 2015-04-15 | 佛山市顺德区北航先进技术产业基地有限公司 | Inorganic fiber reinforced heat insulation board |
| CN105367095A (en) * | 2015-11-19 | 2016-03-02 | 长兴兴鹰新型耐火建材有限公司 | Fireproof pouring material used for cement kiln tertiary air duct and preparation method thereof |
| CN106370010A (en) * | 2016-08-31 | 2017-02-01 | 安徽芜湖海螺建筑安装工程有限责任公司 | Novel liner structure implementation scheme for cement kiln opening |
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